A reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, and method for the construction thereof

ABSTRACT

The invention relates to a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, comprising a pre-formed main cast stone body integrally provided with a pre-fabricated reinforcing structural framework to which other structural element is attached, and a means for mounting said structure. A detachable and replaceable top cover, whose features can be made to suitably match with the design of the house or main structure to which the said outdoor structure is associated with, is provided to embodiments in forms of hollow post and mailboxes. The method for the construction thereof comprises the steps of pre-forming and pre-casting the said main cast stone body, including said top cover for certain embodiments, separately pre-fabricating of said reinforcing structural framework, and mounting integrally and fixedly said structural framework into the pre-formed main cast stone body by a bonding means for posts and mailboxes, and an attaching means for address plaques.

BACKGROUND OF INVENTION

[0001] The invention generally relates to molded or cast products and more particularly to a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, and method for construction thereof.

[0002] Conventional outdoor structures of the type as herein identified, which include entranceways, freestanding posts, planters, address posts and plaques, mailboxes and similar structures, are usually made of solid concrete block, bricks or stone. Thus, such structures cannot be installed, transported or constructed with facility on site. As roadside structures, they present a serious safety hazard when struck by vehicles. Furthermore, these structures have much limitations when it comes to design consideration and aesthetic appeal which are equally important in providing a pleasing appearance to the house or main structure with which they are associated. As alternative to the conventional structures, Lents U.S. Pat. No. 4,875,622 provided a lightweight breakaway freestanding structure that is formed from a block of styrofoam, coated with successive layers of a mixture of stucco and lightweight aggregate filler, and provided with an outer layer that resembles faces of brick, stone or other masonry elements. Although much lighter than the conventional structures, this breakaway structure has a relatively lower durability and strength factors due to its styrofoam substrate. A similar outdoor structure having a substrate also made of foam plastic is disclosed in Sugiyama U.S. Pat. Nos. 5,713,561, 5,836,572, and 5,685,523. In this patent, artificial stones are adhesively fixed into the substrate using nails partly embedded and projecting out from the rear surface thereof. For reference to other prior art teachings on outdoor structures, attention is also directed to the Hancovsky U.S. Pat. No. 5,363,609, Wasson U.S. Pat. No. 6,185,888 and Virgili U.S. Pat. No. 4,496,511.

SUMMARY OF INVENTION

[0003] The present invention provides a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, that is lightweight yet highly durable, with the required strength to withstand attachment loads such as metallic fences and transverse connectors. Its homogeneous, cast stone main component having natural-stone-looking surface textures, roughness, cracks and colors makes it abrasion and dentition resistant. It is provided with reinforcing structural framework for mounting and stability purposes when installed as freestanding structure such as mailbox or address post, or as supporting post or pillar for fences, entranceways or similar structures. Further, with the provision thereto of a detachable top covering which can have a variety of designs, forms, textures, colors and shapes, the present invention has an inherent adaptation capability to suitably match or blend with the design and appearance of the house or main structure to which it is associated with.

[0004] The method for construction of the present invention comprises of steps that are most practical and economical in the manufacture thereof wherein a separately pre-fabricated reinforcing structural framework is fittingly inserted, mounted and cast in place into the inner section of the pre-formed main cast stone structure.

[0005] It is therefore a primary object of this invention to provide a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, that is made predominantly of pre-formed main cast stone with natural-stone-looking appearance in terms of texture, color, roughness and crack occurrences, that is provided with reinforcing structural framework for load-bearing and durability purposes, and detachable versatile top cover to suitably match the user's design choice or preference, and a mounting means.

[0006] Another object thereof is to provide a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like that is capable of being transported, handled and installed in a facile way.

[0007] Still another object thereof is to provide a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like that is highly safe in its applications as roadside structure, and most elegant to view at as pillar or freestanding post in entranceways with its classical style and natural-stone-looking appearance.

[0008] Yet another object thereof is to provide a method for the construction of a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like, that is very simple and most practical, thus facilitating an economical manufacture of the outdoor structure utilizing only indigenous materials and simple technology or craftsmanship.

BRIEF DESCRIPTION OF DRAWINGS

[0009] Other objects, features and advantages of the invention will be better understood and appreciated from the following detailed description which is made in conjunction with the appended drawings, in which: FIG. 1 is a perspective view of a preferred embodiment of the invention; FIG. 2a 1 is an exploded, perspective view showing the reinforcing structural framework and a cut-away portion of the main cast stone body thereof as referred to FIG. 1; FIG. 2a 2 is a plan view of bracing variation of said reinforcing structural framework in a form of criss-crossing transverse bars; FIG. 2b is a cross-sectional view thereof taken along line 2-2 of FIG. 1 with a provision of a means for mounting the invention; FIG. 3 is a perspective view of another embodiment of the invention in a form of a post type mailbox; FIG. 4 is a cut-away, perspective view of a variation of the mailbox shown in FIG. 3; FIG. 5 is a perspective view of still another embodiment of the invention in a form of a wall-mounted mailbox; FIGS. 6a, 6 b, and 6 c are perspective views of top covers of post and mailbox versions thereof in different designs; FIGS. 7 to 12 are perspective views of illustrative examples of possible applications and other embodiment forms or versions of the present invention such as gate post or entranceways, address post, mailbox, and address plaques.

DETAILED DESCRIPTION

[0010] Before describing the preferred embodiments of the invention in detail, it is to be understood that the phraseologies and terminologies employed herein are for purposes of description and should not be regarded as limiting.

[0011] Referring now to the drawing in which like reference numerals designate the same parts or elements all throughout the succeeding description, there is shown in FIG. 1 a preferred embodiment, in a form of a hollow post 16 of a pre-fabricated, reinforced cast stone outdoor structure such as gate, fence, garden and address posts, address plaques, mailboxes or the like generally designated by reference numeral 10, comprising a pre-formed main cast stone body 11, a pre-fabricated reinforcing structural framework 12 which also facilitates attachment of other structural elements 16 b such as fence structural bars 16 b 1 (shown in FIGS. 2b and 7), a detachable and replaceable top cover 13, and a means 14 for mounting the outdoor structure 10 (shown in FIG. 2b).

[0012] The pre-formed main cast stone body 11 is preferentially made of resin-bonded fine or granulized material such as an admixture of calcium carbonate, resin-based adhesive and hardener, and pigments. The said admixture is applied into a mold (not shown), preferably manually; resulting to the cast stone body 11 that is characterized by natural-stone-looking (preferably Mactan stone or fossilized-stone-looking) surface textures, roughness, crack occurrences and colors. The pre-formed main cast stone body, when hollow, can be made stronger by integrally interposing and embedding into the surface of the hollow inner section 10 a thereof, a strengthening material 15 selected from wire mesh, textile, fabric, fiberglass mat and gauze-like materials. The provision of the hollow inner section 10 a is purposely for the reduction of weight of the resulting cast stone product or structure 10. For relatively smaller molded product or article, it is preferably not provided with strengthening means 15 since the required body strength thereof is sufficient enough for its intended usage. A liquid-sealing means (not shown) is also provided thereto for applications that requires liquid or water retainment, in a form of impermeable sheet element such as plastic sheet or similar material which is also integrally interposed and embedded therein just like the strengthening material 15.

[0013] The reinforcing structural framework 12, which is pre-fabricated using flat or angle bars 12 a preferably made of metal such as aluminum, steel, brass, or wrought iron, or any suitable rigid material being adjoined together in a pre-determined configuration by fastening means such as welding, bolts and nuts, etc., is fittingly inserted into the hollow section 10 a through a top opening 10 b of the main body 11, and is fixedly and integrally bonded thereto by a bonding means 12 b preferably in a form of fiberglass and resin mixture as adhesive bonding material. Once bonded and set in place, the structural framework 12 supports, strengthens and reinforces the main body 11, especially when the resulting structure is used as supporting post for fences, gate or entranceways or the like. Other structural elements 16 b are connected to the posts 16 through their respective connecting means 16 a provided to the structural frameworks 12 thereof which are preferably made of steel bars. The structure 10 has the bases of the cast stone body 11 and framework 12 thereof, or the means 14 for mounting the outdoor structure 10 that is secured to the framework 12, being stably and fixedly mounted on a concrete base or foundation 20 as shown in FIG. 2b, or directly into the ground.

[0014] The means 14 for mounting the outdoor structure 10 is preferably in a form of a mounting rod 18 as shown in FIG. 2b, having an upper portion that is securely fitted into an integral sleeve 19 of the framework 12, and a lower portion being pierced into the ground or fixedly secured into a concrete base or foundation 20. As mentioned above, the mounting means 14 can also be in a form of a fixed and stable installation of the bases of both the cast stone body 11 and structural framework 12 into a concrete foundation as shown in FIG. 2b.

[0015] The reinforcing structural framework 12 can also be integrally incorporated externally into the cast stone body 11 in applications such as address plaques shown in FIGS. 10, 11 and 12. This framework 12 version, which is upwardly and downwardly provided with other structural element attachment 16 b in a form of decorative metal works 16 b 2, is integrally and fixedly attached to the peripheral edge of the cast stone body 11 by an attaching means 12 c.

[0016]FIGS. 3 and 4 show another preferred embodiments of the structure 10 in a form of a post type mailbox 21 that is provided integrally at the upper portion of the main body 11 and structural framework 12 thereof with a mailbox structural compartment 22 having an opening 23 at the front side thereof that is provided with a corresponding door 24 hingedly secured thereto. FIG. 4 shows the mailbox 21 having a rounded top portion. The door 24 may be made of metal, fiberglass, cast stone or any suitable materials. The structural framework 12 is fittingly inserted, and fixedly and integrally bonded in place by the bonding means 12 b into the inner hollow section 10 a of the mailbox 21 just like that of the post 16. FIG. 7 illustrates the post 16 being provided with a mailbox 22 a at the upper portion thereof.

[0017] The present invention also embodies another version of a mailbox 25 shown in FIG. 5 that is preferably provided with a top cover 13 being fixedly secured thereto. The mailbox 25 that has a box-type form or design can be mounted on walls 25 a or put on a separate platform or upstanding structure, e.g. an ornamental post 26, as shown in FIG. 9.

[0018] The top cover 13, which can cater design choice that suitably matches with the house or main structure design, can adopt and have a variety of designs, forms, textures, colors and shapes desired. Illustrative examples of top cover designs are shown in FIGS. 6a, 6 b, and 6 c. This top cover 13 is detachably fitted into the top opening 10 b of the pre-formed main cast stone body 11 to facilitate later changes in its design as shown by post 16 in FIG. 2b, or fixedly mounted in as shown by mailbox 25 in FIG. 5.

[0019] FIGS. 7 to 12 depict some of the applications, embodiments or forms of the present invention in which FIG. 9 shows the mailbox 25 being seated on top of an ornamental post, FIG. 8 illustrates an address post 27 with an address indicia 28 provided at the front side thereof, and FIGS. 10, and 11 to 12 show address plaques 29, and 30 a to 30 b, that are ground-mounted and wall-mounted, respectively, and are having respective address indicia 28 a. FIG. 7 shows an entranceway consisting of posts 16 utilized as gate and fence supporting posts, and connected respectively by fence structural bars 16 b 1. The embodiments of the invention or structure 10, in forms of mailbox and address plaque shown in FIGS. 9 to 12, are capable of being seated on separate upstanding structural platform 26 as previously mentioned in the case of mailbox 25 (FIG. 9, mounted on walls 25 a as in the case of mailbox 25 and address plaques 30 a and 30 b, and on a base or foundation through supporting rods 29 a fixedly provided downwardly of the address plaque shown FIG. 10.

[0020] The method for the construction of the present invention comprises the steps of: a. pre-forming and pre-casting the main cast stone body 11, including the top cover 13 for hollow posts and mailboxes, using respective molds of pre-determined structural features, i.e. size, forms, configuration, etc., by manually applying the admixture of calcium carbonate, resin-based adhesive and hardener, and pigments into the mold. For relatively large structure 10, a strengthening material 15 is bonded to the inner surface of the cast stone body 11 before mounting the structural framework 12 thereinto. Optionally, for applications requiring leak-proofing, a water-sealing means 16 is bonded between the inner surface and the strengthening material; b. drying and curing the main cast stone body 11, and the top cover 13 if included, in their respective molds; c. removing the pre-formed main cast stone body 11, and the top cover 13 if included, from their respective molds, and preparing the cast stone body 11 for the mounting of said structural framework 12; d. pre-fabricating the structural framework 12 in accordance with the preferred dimensional, usage and design requirements and specifications suited for certain applications, embodiments and forms of the outdoor structure 10; and e. mounting the structural framework 12 into the pre-formed main cast stone body 11 in the following ways, namely: (1) for hollow post and mailbox embodiments of the invention, by insertably, integrally and fixedly mounting the framework 12 into the hollow inner section 10 a of the cast stone body 11 with the use of the bonding means 12 b preferably in a form of fiberglass and resin mixture as adhesive bonding material; and (2) for an address plaque embodiment, by integrally and fixedly mounting the framework 12 into the cast stone body 11 with the use of the attaching means 12 c in a form of spikes 12 d being pierced and cast into respective apertures along the peripheral edge thereof as shown in FIGS. 11 and 12.

[0021] Before defining the scope of the following claims, it is to be understood that the invention is not limited in its application to the details of construction or structure of the components/elements set forth in the preceding description or illustrated in the drawings. It is to be noted that the invention is capable of other embodiments and limitless applications not disclosed herein, and of being practiced and carried out in various ways falling within the teaching and scope of the following claims. 

1. A pre-fabricated, reinforced cast stone outdoor structure in a form of gate, fence, garden and address posts, address plaques, mailboxes or the like, comprising: a pre-formed main cast stone body; a pre-fabricated reinforcing structural framework integrally provided to said pre-formed cast stone body; which facilitates attachment of other structural elements to the structure; and a means for mounting said structure.
 2. A structure according to claim 1, in a form of a hollow post, wherein said reinforcing structural framework is fittingly inserted, and fixedly and integrally bonded in place by a bonding means into the inner hollow section of said post.
 3. A structure according to claim 1, in forms of hollow post with a provision of a mailbox at the upper portion thereof or post type mailbox, wherein said reinforcing structural framework, being provided with a mailbox structural compartment, is fittingly inserted, and fixedly and integrally bonded in place by a bonding means into the inner hollow section of said post.
 4. A structure according to claim 1, in a form of a planar address plaque, wherein said reinforcing structural framework is integrally and fixedly attached to the peripheral edge thereof by an attaching means.
 5. A structure according to claim 1 wherein said reinforcing structural framework consists of metal bars fixedly adjoined together in a pre-determined configuration.
 6. A structure according to claim 1 wherein said means for mounting said structure is in a form of a mounting rod having an upper portion that is securely fitted into an integral sleeve provided to said framework, and a lower portion being pierced into the ground or fixedly secured into a concrete base or foundation.
 7. A structure according to claim 1, wherein said means for mounting said structure is in a form of a fixed and stable installation of the bases of both said structure and structural framework into a concrete foundation.
 8. A structure according to claim 1, in a form of an address post, wherein an address indicia is fixedly attached at the front side thereof.
 9. A structure according to claim 6, wherein said structure is in a form of an address post.
 10. A structure according to claim 1, wherein a connecting means is provided to said reinforcing structural framework to facilitate attachment of other structural elements to the structure.
 11. A structure according to claim 1, in forms of mailbox and address plaque, wherein said structure is capable of being seated on separate upstanding structural platform, mounted on walls or on a base foundation through supporting rods fixedly provided downwardly thereof.
 12. A structure according to claim 1, in forms of hollow post and mailbox, wherein there is provided a top cover capable of adopting a variety of designs, forms, textures, colors and shapes that suitably matches with the house or main structure design with which the said outdoor structure is associated with, said top cover being detachably fitted securely into the top opening of the pre-formed main cast stone body.
 13. A structure according to claim 1 wherein said pre-formed main cast stone body is made from an admixture of calcium carbonate, resin-based adhesive and hardener, and pigments, and characterized by natural-stone-looking surface textures, roughness, crack occurrences and colors.
 14. A structure according to claim 13, wherein a strengthening material is adhesively bonded to the inner surface of the pre-formed main cast stone body.
 15. A method for the construction of a pre-fabricated, reinforced cast stone outdoor structure in a form of a gate, fence, garden and address posts, address plaques, mailboxes or the like comprising the steps of: a. pre-forming and pre-casting a main cast stone body using a mold of pre-determined structural features; b. drying and curing the main cast stone body in said mold; c. removing the pre-formed main cast stone body from the mold, and preparing same for the mounting of said structural framework; d. pre-fabricating a structural framework, including a means for mounting said structure, in accordance with the preferred dimensional, usage and design requirements and specifications suited for specific applications and embodiments of the outdoor structure; and e. mounting integrally and fixedly said structural framework into the pre-formed main cast stone body.
 16. A method according to claim 15 wherein said pre-formed main cast stone body is made from an admixture of calcium carbonate, resin-based adhesive and hardener, and pigments.
 17. A method according to claim 15, further comprising the step of bonding a strengthening material to the inner surface of the pre-formed main cast stone body before mounting said structural framework there into.
 18. A method according to claim 15, further comprising the step of pre-forming and pre-casting a top cover using a mold of pre-determined structural features.
 19. A method for the construction of a structure according to claim 15, in a form of hollow post and mailbox, wherein said structural framework is insertably, integrally and fixedly mounted into the hollow inner section of the pre-formed main cast stone body by using a bonding means in a form of fiberglass and resin mixture.
 20. A method for the construction of a structure according to claim 15, in a form of an address plaque, wherein said structural framework is integrally and fixedly mounted into the pre-formed main cast stone body by using an attaching means in a form of spikes being pierced and cast into respective apertures on the peripheral edge thereof. 